BlueSolar charge controller MPPT 100/30 - Top Systems 1.1 Charge current up to 30A and PV voltage up

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Transcript of BlueSolar charge controller MPPT 100/30 - Top Systems 1.1 Charge current up to 30A and PV voltage up

  • Manual

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    BlueSolar charge controller MPPT 100/30

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    1. General Description

    1.1 Charge current up to 30A and PV voltage up to 100V The BlueSolar MPPT 100/30 charge controller is able to charge a lower nominal-voltage battery from a higher nominal voltage PV array. The controller will automatically adjust to a 12 or 24V nominal battery voltage.

    1.2 Ultra-fast Maximum Power Point Tracking (MPPT) Especially in case of a clouded sky, when light intensity is changing continuously, an ultra fast MPPT controller will improve energy harvest by up to 30% compared to PWM charge controllers and by up to 10% compared to slower MPPT controllers.

    1.3 Advanced Maximum Power Point Detection in case of partial shading conditions If partial shading occurs, two or more maximum power points may be present on the power-voltage curve. Conventional MPPT’s tend to lock to a local MPP, which may not be the optimum MPP. The innovative BlueSolar algorithm will always maximize energy harvest by locking to the optimum MPP.

    1.4 Outstanding conversion efficiency No cooling fan. Maximum efficiency exceeds 98%. Full output current up to 40°C (104°F).

    1.5 Extensive electronic protection Over-temperature protection and power derating when temperature is high. PV short circuit and PV reverse polarity protection. PV reverse current protection.

    1.6 Internal temperature sensor Compensates absorption and float charge voltages for temperature.

    1.7 Automatic battery voltage recognition The MPPT 100/30 will automatically adjust itself to a 12V or a 24V system.

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    1.8 Flexible charge algorithm Eight preprogrammed algorithms, selectable with a rotary switch. 1.9 Adaptive three step charging The BlueSolar MPPT Charge Controller is configured for a three step charging process: Bulk – Absorption – Float. 1.9.1. Bulk stage During this stage the controller delivers as much charge current as possible to rapidly recharge the batteries. 1.9.2. Absorption stage When the battery voltage reaches the absorption voltage setting, the controller switches to constant voltage mode. When only shallow discharges occur the absorption time is kept short in order to prevent overcharging of the battery. After a deep discharge the absorption time is automatically increased to make sure that the battery is completely recharged. Additionally, the absorption period is also ended when the charge current decreases to less than 2A. 1.9.3. Float stage During this stage, float voltage is applied to the battery to maintain it in a fully charged state. 1.9.4. Equalization See section 3.7.1 1.10 Connectivity See section 3.8 of this manual 1.11 Remote on-off The MPPT 100/30 can be controlled remotely by a VE.Direct non inverting remote on-off cable (ASS030550300). An input HIGH (Vi > 8V) will switch the controller on, and an input LOW (Vi < 2V, or free floating) will switch the controller off. Application example: on/off control by a VE.Bus BMS when charging Li-ion batteries. 1.12 Real-time data display on Apple and Android smartphones, tablets and other devices VE.Direct Bluetooth Smart dongle and VictronConnect app needed: see section 3.8.

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    2. Safety instructions

    ● Please read this manual carefully before the product is installed and put into use. ● This product is designed and tested in accordance with international standards. The equipment should be used for the designated application only. ● Install the product in a heatproof environment. Ensure therefore that there are no chemicals, plastic parts, curtains or other textiles, etc. in the immediate vicinity of the equipment. ● Ensure that the equipment is used under the correct operating conditions. Never operate it in a wet environment. ● Never use the product at sites where gas or dust explosions could occur. ● Ensure that there is always sufficient free space around the product for ventilation. ● Refer to the specifications provided by the manufacturer of the battery to ensure that the battery is suitable for use with this product. The battery manufacturer's safety instructions should always be observed. ● Protect the solar modules from direct light during installation, e.g. cover them. ● Never touch uninsulated cable ends. ● Use only insulated tools. ● Connections must always be made in the sequence described in section 3.5. ● The installer of the product must provide a means for cable strain relief to prevent the transmission of stress to the connections. ● In addition to this manual, the system operation or service manual must include a battery maintance manual applicable to the type of batteries used.

    Danger of explosion from sparking Danger of electric shock

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    3. Installation 3.1 General ● Mount vertically on a non-flammable surface, with the power terminals facing downwards. ● Mount close to the battery, but never directly above the battery (in order to prevent damage due to gassing of the battery). ● Use cables with at least 10mm² or AWG6 cross section. The recommended maximum length of the cable is 5m, in order to restrict cable loss. (if the cables to the PV panels must be longer than 5m, increase cross section or use parallel cables and install a junction box next to the controller and connect with a short 10mm² or AWG6 cable to the controller). ● Grounding: the heat sink of the controller should be connected to the grounding point. ● Use one grounding point only (preferably close to the battery, for safety reasons) to which the battery negative or battery positive should be connected. Do not also connect the solar array negative to ground. This would result in unwanted ground currents 3.2 PV configuration (also see the MPPT Excel sheet on our website) ● The controller will operate only if the PV voltage exceeds battery voltage (Vbat). ● PV voltage must exceed Vbat + 5V for the controller to start. Thereafter minimum PV voltage is Vbat + 1V. ● Maximum open circuit PV voltage: 100V. The controller can be used with any PV configuration that satisfies the three above mentioned conditions. For example: 12V battery and mono- or polycristalline panels ● Minimum number of cells in series: 36 (12V panel). ● Recommended number of cells for highest controller efficiency: 72 (2x 12V panel in series or 1x 24V panel). ● Maximum: 144 cells (4x 12V or 2x 24V panel in series).

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    24V battery and mono- or polycristalline panels ● Minimum number of cells in series: 72 (2x 12V panel in series or 1x 24V panel). ● Maximum: 144 cells. Remark: at low temperature the open circuit voltage of a 144 cell solar array may exceed 100V, depending on local conditions and cell specifications. In that case the number of cells in series must be reduced. 3.3 Cable connection sequence (see figure 1) First: connect the battery. Second: connect the solar array (when connected with reverse polarity, the controller will heat up but will not charge the battery). 3.4 More about automatic battery voltage recognition The system voltage is stored in non volatile memory. In case of a 24V battery, a reset (to 12V) occurs only when output voltage decreases to less than 2V and voltage on the PV input exceeds 7V. This may occur if the battery has been disconnected before PV voltage starts to rise in the early morning. When the (24V) battery is reconnected later during the day, the system voltage is restored to 24V after 10 seconds if the battery voltage exceeds 17,5V. Automatic voltage recognition can be switched off and a fixed 12V or 24V system voltage can be set with the VictronConnect app (see sect 3.8): recommended if the battery is frequently disconnected from the controller. The controller can be reset by short circuiting the output and applying a voltage exceeding 7V on the input (for example with a small power supply, or a solar panel) during a few seconds. After a reset, the controller will automatically adjust itself to a 12V system or a 24V system (when connecting a 24V battery with at least 17,5V).

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    3.5 Configuration of the controller Fully programmable charge algorithm (see the software page on our website) and eight preprogrammed charge algorithms, selectable with a rotary switch:

    Pos Suggested battery type Absorption V

    Float V

    Equalize V

    @%Inom dV/dT mV/°C

    0 Gel Victron long life (OPzV) Gel exide A600 (OPzV) Gel MK

    28,2 27,6 31,8 @8%

    -32

    1

    Gel Victron deep discharge Gel Exide A200 AGM Victron deep discharge Stationary tubular plate (OPzS) Rolls Marine (flooded) Rolls Solar (flooded)

    28,6 27,6 32,2 @8%

    -32

    2

    Default setting Gel Victron deep discharge Gel Exide A200 AGM Victron deep discharge Stationary tubular plate (OPzS) Rolls Marine (flooded) Rolls Solar (flooded)

    28,8 27,6 32,4 @8%

    -32

    3 AGM spiral cell St